2013

Muhammad Fasih WaheedSohaib AhmedSyed Hayder

Internship Report

ACKNOWLEDGMENT

An attempt over a period can be successful only with the advice and support of well

wishers. We take this opportunity to express our gratitude to all those who encouraged

and helped us to complete the tasks of this internship.

We are deeply indebted to Sir. MUHAMMAD JAMSHED and Sir FIDA HUSSAIN, for

our successful completion of internship.

We express our profound and sincere thanks to Miss ZEHRA who acted as mariner’s

compass and steered us throughout our internship journey through her excellent

guidance and constant inspiration.

We shall be failing our duty if we don’t acknowledge our debt to Mr. MUHAMMAD

TALHA, Mr. ASIM RAUF, Mr. KAPIL DAVE, for their valuable counseling and support,

which helped us giving a shape to our study.

We also extend our thanks to all other TSMLE members for their support and

encouragement.

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EXECUTIVE SUMMARY

This internship report consists of four sections; the first section is introduction to TSML

which include organization’s history, background, vision, mission Introduction of

TSMLE and TSMLE Solar. The second section covers assignments which include solar

cell types, working, construction, brief information about inverters, batteries and

mounting structures, Visuals are also included for better understanding. Third section

entirely consists of solar system designing according to the load. Fourth section discusses

the successful projects like SHADMAN MALL, BEACON HOUSE SCHOOL SYSTEM

LAHORE campus, the inverters, batteries and other equipments that were used in these

projects.

In the end handouts of PLC, Actuators, Thermocouple and RTD’s are attached and are

part of this report.

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Contents

ACKNOWLEDGMENT.....................................................................................................2

EXECUTIVE SUMMARY.................................................................................................3

ABOUT TSML....................................................................................................................5

TSML DEPARTMENTS.....................................................................................................6

TSML ENGINEERING KARACHI (TSMLE)...................................................................6

TSMLE SOLAR..................................................................................................................7

ASSIGNMENTS...............................................................................................................12

PHOTO VOLTAIC MODULES.......................................................................................12

MOUNTING STRUCTURES...........................................................................................14

INVERTERS.....................................................................................................................14

INVERTERS OFFERED BY TSMLE..............................................................................15

BATTERIES......................................................................................................................16

SOLAR SYSTEM DESIGNING.......................................................................................17

SOLAR PROJECTS..........................................................................................................18

1. 40 KW ROOF TOP SOLAR SYSTEM (SHADMAN SHOPPING MALL )...........18

SYSTEM RATINGS.........................................................................................................18

2. 10KW ONGRID SOLAR SYSTEM AT BEACON HOUSE CANAL CAMPUS LAHORE...........................................................................................................................19

IMPORTANT FORMULAE.............................................................................................20

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ABOUT TSML

AL TUWAIRQI holding is a prestigious Saudi Arabian industrial conglomerate, which

has interests in steel and engineering and ranked 26th among top hundred companies of

the kingdom with the rating of 2nd fastest growing group ATH’s core business include

iron and steel production, steel products manufacturing, electrical manufacturing, power

generation and engineering.

In engineering ATH has a strong presence in the region of KSA, UAE and Pakistan. The

group comprises five separate entities unified under one flag i.e. Al TUWAIRQI holding,

to form a resource pool, which offers multi dimensional services to our clients, TSMLE

Engineering Pakistan is one of them.

TSML DEPARTMENTS 1. Administration2. Finance department3. It department4. Procurement5. Electrical and instrumentation6. Mechanical engineering7. Process engineering8. Civil engineering9. Cad department10. Pmo department11. Sales and marketing

TSML ENGINEERING KARACHI (TSMLE)

TSMLE Karachi is an engineering company involved in engineering designs, fabrication

and erection of products related to oil and gas, fertilizers, petrochemicals, power

generation and process industry. TSMLE acts as a design engineering hub for the ATEG

and has to its major credit complete “out side the licensor scope” design and 50% of

fabrication of DRI plant, a state-of-the-art-steel manufacturing complex in Pakistan, at

Port Bin Qasim Karachi.

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TSMLE is gearing up to market its engineering design and fabrication capabilities in

Pakistan, with objective to maintain a sustainable growth with one underlying principal;

to combine the multifaceted capabilities and energies of people, partners, entrepreneurs,

community and stakeholders, in order to form an alliance which one could create its own

excellence in the services spectrum. In Pakistan we have already developed business

relationship with prestigious names such as ENGRO, Bayer PHARMA, KPT, BYCO and

KSEW.

Besides providing design service to group, TSMLE ambitiously expending its operations

in Pakistan, with primary focus on prestigious customers who nurture quality.

AL TUWAIRQI engineering companies have strategy alliances with a number of

internationally renowned engineering companies operating in the region such as SACDO,

SPCEO and FL smith. Under these J-V agreements the partners would synchronize their

expertise to provide the best yet cost effective solution to our customers.

At group level our existing external customers include illustrious names such as Saudi

ARAMCO, Qatar Steel, SABIC, Saudi electricity company, WINDHOFF, ADNOC, and

ENGRO etc. At group level, we have provided complete EPC solution to our subsidiaries

in Saudi Arabia, UAE and Pakistan,

We are committed to set the high quality standards. The group already conforms to the

international quality management standards (ISO 9001:2008) , Hence begin capable of

meeting all quality marks and international standards.

TSMLE SOLARTSMLE SOLAR is a subsidiary of Tuwairqi Steel Mills Limited, TSMLE SOLAR is one of the largest Solar Systems integrators and services providers in Pakistan, with special expertise in design and installation of commercial solar systems. With its in-house mechanical fabrication facility, dedicated design and executions teams, a vast team of experienced professionals and technical personnel, Simulation and testing facilities, TSMLE SOLAR is dedicated to deliver best quality services and solutions to its customers. TSMLE SOLAR has been continuously working to develop innovative

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solutions to play its part in the collective effort to meet the ever increasing energy demands while constantly striving for nature and environment conservation by providing clean and green energy. TSMLE SOLAR is ISO 9001:2008 certified and believes in constant quality improvement and delivering the best quality of services to the utmost satisfaction of its clients.

TSMLE DESIGN ENGINERING SERVICES

TSMLE is capable of multidisciplinary and multidimensional design engineering services

in the core business sector like

Crude oil refining

Oil storage terminals

Natural gas processing

Fertilizer

Cement

Steel

Petrochemicals

Power generation

Process industry

TSMLE have multidisciplinary engineering teams, i.e. Process, Mechanical and piping,

civil and structure, E&I.

VISION

Our vision for TSMLE is its transformation into an international market leader equipment

manufacturing and multifaceted engineering service we envisage to grow as a company

which acquire a place among the best in the business and retains the place by

continuously delivering world class engineering services to the utmost satisfaction of our

valued customers, and at the same time bringing new technologies to our nation and

contribute to its economic growth.

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MISSION

Our mission of TSMLE is to transform it in one stock solution provider in design

engineering, Equipment manufacturing, construction, Fabrication and maintenance

services by offering best quality and optimal cost.

To accomplish our goals we are already geared; By inducting the best human resource,

providing rigorous professional training creating a conductive work environment and

establishing a culture where striving for the not lesser than the best is the order of every

day!

VALUESWe endeavor to be a respected world-class organization and the leader in Pakistan’s steel

industry by:

• Fostering teamwork

• Delivering premium products & services

• Nurturing talent

• Developing solutions based on cutting-edge technologies

• Respecting the environment

• Caring for our community

Demonstrating high ethical standards

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CORPORATE VALUES

SERVICES OFFERED:

Solar Module design and installation. Engineering design services. Direct Reduced Iron from DRI plant.

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ORGANOGRAM OF TSMLE ENGINEERING

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BASIC DESIGN

P&ID and Speciation’s

Instrument and device locations

Single line diagram

DCS Configuration design

Interconnection design

DETAIL ENGINEERING Load calculations and cable sizing

Switch gear selection instruments hook ups

Wiring diagrams and schematics

Earthling and grounding

Cable schedule and cable details

Equipment layout drawing

Electrical co ordinations and short circuit studies

TSMLE have multidisciplinary engineering teams, i.e. process, Mechanical and piping,

civil and structure, E&I These terms comply of individuals who blend extensive past

experience in designing and detail engineering of relevant fields, Exposure to

international engineering codes and practices and modern engineering tools, working

with renowned licensers and serving prestigious clientele.

The attitude of constant knowledge sharing and flexibility of technology adoption are

inherent of TSMLE team members who are constantly progressing towards gaining

expertise and utilizing the skills to the utmost in their respective fields of engineering.

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ASSIGNMENTS

PHOTO VOLTAIC MODULES

A complete PV (photo voltaic) Module consists of PV cells, Inverter, batteries, battery

charging circuitry and mounting structure. The PV cell converts photons produced by the

sun to electrons (electricity) on the basis of a simple process called “The photo electric

effect”. The inverter converts the DC signal produced by the panel to AC signal and in

some cases also acts as a charge regulator for batteries. A mounting structure mounts the

PV panel on a degree at which maximum Sun light is accessible.

CONSTRUCTION

PV cells are constructed of Silicon semi conductors. These silicon layers are sandwiched

between two protective layers and are bordered depending upon the power we would like

to extract from them. One side of the protective layer is transparent from which the

photons are allowed to enter. In the end set of these PV cells are connected in series or

parallel depending upon the requirement.

TYPES OF PV CELLSThere are two types of PV cells

Mono crystalline Poly crystalline

Mono Crystalline

Mono Crystalline consist of single crystal

Of silicon which is way more efficient and

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Harnesses more energy from the sun compared

To poly crystalline but is costly and lacks

Flexibility.

POLY CRYSTALLINE

Poly Crystalline cells are made up of millions

and billions of Silicon crystals that are combined

to form poly crystalline cell, It is cheap

and flexible to use but less efficient when it

comes to power output.

WORKING OF PV CELLS

As the photon from sun strikes to the surface of PV silicon cell. The barrier potential of

Silicon PN-junction is disturbed causing an imbalance in electrons and holes of upper

band and lower band of PV cell. This imbalance creates a potential difference across the

ends of PV cell hence delivering usable electricity.

MOUNTING STRUCTURESMounting structures are an essential part of a solar system; they hold the PV cells and tilt

them at the required angle to expose cells to maximum

Sunlight, Currently TSMLE Solar is working as a

Distributor of Solar world mounting structures.

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TYPES OF MOUNTING STRUCTURES Fixed Racks Horizontal one-axis tracking system Tilted one-axis tracking system Rail tracking system

INVERTERS

MODIFIED SIN WAVE INVERTER Modified sin wave inverters are cheap and common however

they have some strong drawbacks. Modified sin wave inverters

are able to run appliances like refrigerator, hand tools, computers

. But they fail to run gaming systems, plasma display and complex

scientific testing systems.

PURE SIN WAVE INVERTER

Pure sin wave inverters are way expensive as compared to modified sin wave inverters

but they are more efficient, they are able to produce pure sin wave and there efficiencies

are up to 98%. Pure sin wave inverters can run high end audio Ideal units, plasma

displays etc too without any problem.

HYBRID INVERTERS

An inverter is an electrical device that converts electricity derived from a DC (Direct

Current) source to AC (Alternating Current) that can be used to drive an AC appliance.

The theory of operation is relatively simple. DC power, from a hybrid battery for

example, is fed to the primary winding in a transformer within the inverter housing.

Through an electronic switch (generally a set of semiconductor transistors), the direction

of the flow of current is continuously and regular broken (the electrical charge travels

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into the primary winding, then abruptly reverses and flows back out). The in/out flow of

electricity produces AC current in the transformer's secondary winding circuit.

Ultimately, this induced alternating current electricity flows into--and produces power

in--an AC load (for example an electric vehicles (EV) electric traction motor). A rectifier

is a similar device to an inverter except that it does the opposite, converting AC power to

DC power.

INVERTERS OFFERED BY TSMLETSMLE is importing inverters from SMA and, Following are some main inverter types;

VOLTRONIC INVERTERS Axpert KS series

SMA INVERTERS

SUNNY MINI CENTRAL SUNNY TRIPOWER SUNNY ISLAND

BATTERIES

TYPES OF BATTERIES:1. VRLA Battery2. Gel type Battery3. Lead Acid Battery

GEL TYPE BATTERY

Gel type batteries are recommended to be used with Solar panels because of their longer

life, lesser danger and deep cycle properties.

LEAD-ACID BATTERYLead Acid Batteries are avoided to be used because of the danger level and poor deep cycle properties.

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VRLA (Valve Regulated) batteryVRLA batteries are being used in solar modules for safer operation. They work on the

basis of LI-Ion batteries

SOLAR SYSTEM DESIGNING

DESIGN OF A SYSTEM CONSIDERING FOLLOWING LOADS:

1. 75 watt fan running for 8 hours2. 20 watt bulb running for 4 hours3. 200 watt TV running 4 hours4. 100 watt computer running 3 hours

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TO CALCULATE WH/DAY

(75*8) + (20*4) + (200*4) + (100*3)

600 + 80 + 800 + 300

1780 * 1.3

2314 Wh/day

PEAK RATING OF PV MODULE

2314/3.43

674.635

NO. OF MODULE

674.635/255 (available solar panel=255 watt)

2.645

3 panels each of 255 watt required

INVERTER SIZING

Total watt = 75+20+200+100 = 395 Watt

395 * 1.3 (for any possible losses)

513.5

600 Watt Inverter

SOLAR PROJECTS

1. 40 KW ROOF TOP SOLAR SYSTEM (SHADMAN SHOPPING MALL )

Client: Ghani Global Groups

SUMMARY

As per drawing we are using 60 PV-modules connected with 3 Sunny mini Central

Inverters to extract power and convert to AC from sun Also we are using 3 sunny island

inverters each connected with set of 24 batteries, these inverters act as a battery backup

system. SMC inverters are synchronized with main AC grid where solar power is given

priority to drive the load.

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SUNNY MINI CENTRAL:

These inverters are connected to PV modules on its DC input channel and to main power

grid on its AC side. It is synchronized with grid and supplies electricity to the load, Here

SMC is given priority to drive the load.

SUNNY ISLAND INVERTER:

Sunny island inverter is a multipurpose inverter, It supplies power from AC to the level

batteries can be charged in DC, Also it converts DC to AC so charged batteries could

supply power to the load.

SYSTEM RATINGSSunny mini Central

11KW, 230V, 50Hz

Sunny Island inverter

5KW, 230V, 50Hz

Switch box

125Ampere and 12 Ampere fuse

2. 10KW ONGRID Solar system at beacon house canal campus Lahore

Client: Beacon House

SUMMARY:

AS per drawing we are using 10KW, 400V, 50 HZ sunny tripower inverter which is

connected with eight PV modules connected in series/parallel connections. The

connections of PV panels and inverters are protected with fuses of 10 Ampere each,

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Sunny Tripower inverter is synchronized with AC, Solar panels output are given priority

to supply electricity to the load.

For a backup system we have three sunny Island inverters which are 2.2 KW, 230 V

50Hz each connecting 24 batteries each rated 300Ah 2V, These batteries are also

protected by 100 A fuses, The sunny Island inverter is directly connected with grid to

charge the batteries.

PROCEDURE

42 of modules are connected with Sunny Tripower Island inverters when the photon

strikes with the surface of the PV modules it produces DC electricity which is inverted in

3 Phase by Inverter and synchronize with main grid, which enable us to maintain stable

voltage. In this system we are given advantage by three phase c1 connector, If we want to

disconnect the grid we can do it.

Backup system consist of batteries which are connected with three Sunny Island system

these connections are protected by 3(100 A) fuses each these sunny Island inverters

perform multiple tasks it not only converts AC to DC but also DC to AC.

Sunny Island systems are directly connected to the grid to charge the batteries.

When switch on C2 three phase connector it makes sure to disconnect the C1 It helps to

prevent the system from damaging.

IMPORTANT FORMULA E

SOLAR PANEL ENERGY OUTPUT FORMULA

E=A*r*H*Pr

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Where,

A=Area

r=Solar panel yield

H=annual average solar radiation on tilt panel

Pr=Performance ratio (0.5-0.9) avg =0.75

BATTERY CHARGING AND DISCHARGING FORMULA

T= Ah of battery/Ampere of supplyWhere,

T= time in hours

Ah= Ampere hour

Annexure

Presentations attached

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